We found a vintage Thunderbird minibike and are using it as a base for a café racer-style minibike build. We love the slant-engine style of the frame and think this thing is going to look awesome and retain a lot of the vintage flair. In this video we extend the frame and add some support bars, mount the gas tank and customize a generic café racer seat to fit our bike. Thanks to Gopowersports for all the parts we used on this build, links are in the description below!
Thank y’all for watching and be sure to stay tuned for the next step of the build!
MUSIC
Music - Background and Montage Music Is From Endemic Sounds
https://www.epidemicsound.com/
Intro - Jimmi by Andrew Applepie
https://www.youtube.com/watch?v=l1zHz8pYfyQ&ab_channel=AndrewApplepie
MERCH
MERCHANDISE CUSTOM DESIGNED BY YOURS TRULY
https://teespring.com/stores/build-break-repeat
TOOLS
RogueFab Tubing Notcher
https://www.roguefab.com/product/versanotcher-universal-tubing-notcher/
Pro-tools Tubing Bender
https://pro-tools.com/collections/tube-and-pipe-benders
Optrel Crystal 2.0 Welding Mask
https://usa.optrel.com/en/eye_protection_helmets/products/show/crystal20/
Optrel Grinding Mask
https://usa.optrel.com/en/products/augenschutz/helme-zum-schleifen-schneiden/products/show/clearmaxx/
—————PARTS—————
Tillotson 212
https://www.gopowersports.com/212cc-tillotson-hemi-engine/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Wheels
https://www.gopowersports.com/10-black-steel-modular-wheel/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Gas Tank
https://amzn.to/2A2lIiB
Café Racer Seat
https://amzn.to/2Xvyazh

All right, everybody, it's been a little while, since we posted a video, we've been kind of busy with everything going on in the world with online classes, but I hope you all are staying safe and having good luck out there. But we are finally back with another pillow, so let's get it introduced. So this right here is a mid 70s to early eighties neck of Thunderbird minibike and we've got some cool plans. For this thing, we've got a bunch of parts from NGO powers board.

For this thing we have a Tilson that we're gon na build. We have these nice kenda tires. We got a z50 tank off of ebay and then we have a seat that we're gon na have to customize to fit this thing yeah. So this build is gon na be a little bit different.

I hope you, like this slant engine style of this thing and bigger tires. We're gon na go for a stretch and we're trying to make this thing. Look like a cafe racer, so it's gon na be no red tank brown seat and we're gon na have a cool tan cream color for the frame we're really just trying to make this thing as pretty as possible, with some power to back it up. So, let's just get started, it's gon na start by stripping this thing completely down and getting a better idea of how this frame looks.

So the first thing to go is gon na be seat all in Janelle and now it's time to see how this predator looks so that'll look pretty good ha yeah deleted perfect clearance right there. That is stuffed in there. I love the slant to then kind of look at our nesting yeah. That's that's pretty! That's pretty nice right on oh dude, that is killer kind of looks like a little bit of like a sport bike on me.

Yeah now that's massive here, but we'll shorten it. That's gon na get scaled down. Jason's gon na work some magic on sewing there. Okay I'll get that deal well lower the handlebars a little bit and we also got to stretch the back.

So the back tire goes beyond the back of the seat, so it kind of has more of a for example, kind of more like that yeah right now, they're, pretty cool, also free, all enthusiasts. Who really like this to come? See I mean it runs all right and stuff, and it's all good like this is a great stock bike, but that's not really what we do here. I think we are gon na sell this engine on eBay or something though, so. It's not going to get like thrown away or anything, but you know this is kind of more what we do just like that.

I think that's pretty mint. Now I'd really like that, and then we got that the decent amount of space right there remember. You may be really tired up like so we decided to lengthen this thing a little bit, she's a little unstable because it was so narrow, and this thing should have a lot of power so lengthening it is gon na help and it looks really cool. I mean our wheelbase is about as long as I could then be 200 now so no issues there.

Now we need to connect this gap down here. So it's as simple as just cutting a piece of tubing and well totally digging other things. Looking we got this all welded up and it is a little bit it's long and it looks nice, but unfortunately, there's kind of like a big gap in here. That's something we can't fix.
So what we're gon na do is we're adding this kind of triangulation right in here. That's gon na give it a bar fits in just like so, and that's gon na fill in a little bit of the frame, and it's going to give us kind of that. Cafe, racer character line. A lot of them have bars that go back just like that.

Commuters are old seat as y'all can see. It's not that great. It's made out of mostly duct tape, so we bought this seat with hopes that just work, but it's way too big. It's more meant for a motorcycle.

So right now, I'm just taking it apart. I have my template and I'm gon na need to cut down the foam to fit this shape it up nice, yep yeah. Unfortunately, we can't really find a way to staple this down up here with it. Looking nice for the engine or the gas tank but booth seems to work good.

I got you far as welded in then. You got the engine box up so before we do the handlebars we're gon na move this fender a little bit forward so that it pokes out less in the rear kind of like cafe, racers and they're gon na get our handlebars kind of chopped down and angled Down more kind of agitate, look yeah. What are you thinking over so far, though? Definitely looking really cool, I think the stretch and everything's gon na come together really good and make it look like a complete bike. So the fenders off - and we definitely didn't, plan this, but you flip it around.

It fits yeah, that's kind of exactly the knows how we wanted yeah your show it's a before and after just kind of yep. So this is before yeah. It's got that overhang bad yeah after mint, alright guys, I hope, you're getting our idea, so we're kind of going for that asymmetrical look. So we got our new custom handlebars on and the seat that Jason made.

Yeah, that's awesome and with the tank it looks really good. Yeah positioned up it looks kind of goofy. You have big butts on it and oh yeah. That's sweet come on.

Just look! Go to deathtrap cool, so now all we got to do is we'll not let that gas tank and we'll have pretty much exactly so. We welded a bolt to the seat pan right here and that holds in the back, and then we have a bolt welded to the tank coming down through the frame. That's bolted in the front. This thing is super sturdy and the tanks in the right position.

So now seat, just mounts up. Yeah right here, wait to see, reuse, that stock the bolt hole. So it's got three gold hold man, it pretty nice. Now that everything's bolted up we'll get the engine mounted.

So we can get some nice Beauty shots of this thing and then wrap this video up. Thank you for watching. I hope you are liking the direction of this build as much as we are it's turning out really killer. Some of my favorite parts are just how the tank looks with that motor and then I really like the handlebars.
We did, I think it turned out pretty good man. Jason always kills it, of course, with the seat. So let us know in the comments who you're thinking our videos are gon na, be pretty much up to date. Now, just so y'all know like the workings of what we have going on we're actually uh we're actually looking at relocating because we're all getting older and stuff.

You know Joe, was almost done with grad school. We're we're getting that point to kind of move on to the next chapter of little breaker Pete and I think that's going to include a new garage so stay tuned for that that's going to be coming very soon. So, basically, what we're going to do is we have. We have pretty much three really cool builds, including this one that we're going to be posting to basically, hopefully ramp us up for the opening of our new garage.

That's going to include this. The electric car pen of a rotary project so stay tuned, an Instagram for that, but anyways. Thank you all for watching. Thank you.

Go Powersports stay tuned for the rest of this thing. We have a pretty cool idea of how we're going to make it look. Super clean so be sure to stay tuned on Instagram for that for a sneak peek, but thank y'all for watching we'll see you next time. You.


Avatar photo

By YTB

21 thoughts on “Vintage mini bike to cafe racer transformation! part 1 rolling frame”
  1. Avataaar/Circle Created with python_avatars Redstar Redstar says:

    I am curious about two things. I’m new to restoring but I’m working on an old mini bike. I have a predator 212 that has a gas and on top of the engine. Can I just remove that and have a gas tank like you did here? Also how do you get lights on a mini bike with no battery. I assume I could weld on a battery box and install one but what did you do on this bike? Any help is greatly appreciated. I’m learning👍

  2. Avataaar/Circle Created with python_avatars RAWR Motorsports says:

    Need to build you a 10krpm flathead for this bike … check out dynocams website for flathead parts

  3. Avataaar/Circle Created with python_avatars NeoIsrafil says:

    Man, if the gas tank was just a bit flatter instead of being so tall itd be PERFECTLY scaled down. Good job.

  4. Avataaar/Circle Created with python_avatars Drago Werx says:

    I always thought a mini cafe racer would be cool…suddenly my instagram feed was full of pictures of this build, SOOO sweet looking!

  5. Avataaar/Circle Created with python_avatars justin woods says:

    I didn’t know the one guy dressed for the 70s acashion to match the bike he looks like a hippy for the 70s

  6. Avataaar/Circle Created with python_avatars Nick Rudd says:

    Personally speaking from tragic face planting experience… Buy some new low bars, welding them lower is NOT safe.

  7. Avataaar/Circle Created with python_avatars Kai Samuelsen says:

    I don’t know about anybody else but I think you should paint the recoil black

  8. Avataaar/Circle Created with python_avatars Mason S says:

    Finally an original mini bike build! Seeing different engine swaps was getting a bit boring

  9. Avataaar/Circle Created with python_avatars Garchompy _ says:

    the panels below the seat, maybe paint them white? add a little number on them like the racebikes used them for?
    maybe change the colour of the engine/tank to mach each other?

  10. Avataaar/Circle Created with python_avatars Owen Roth says:

    You need to do a collab with cars and cameras once the quarentine is over. I feel like you could make something really cool with that Tecumseh

  11. Avataaar/Circle Created with python_avatars Owen Roth says:

    I would raise the handlebars a little bit, riding it like that might feel pretty awkward.

  12. Avataaar/Circle Created with python_avatars Eric Riddle says:

    Glad to see you guys back at it again, you guys got some talent stay safe out there

  13. Avataaar/Circle Created with python_avatars Phillip Mountain Man says:

    Cool build. IMO you need more bracing on the bottom of the frame. Just saying.

  14. Avataaar/Circle Created with python_avatars MetalMan 329 says:

    Did he say, “Predator???” LOL! Handlebars need a riser…. tank sits higher than the bars… level it out… coming along nicely!

  15. Avataaar/Circle Created with python_avatars mike may says:

    You need to set the foot pegs back to the wheel it would be a more comfortable placement and correct for the cafe style🏁👍🇺🇸

  16. Avataaar/Circle Created with python_avatars Jon C says:

    knobby tires on a cafe racer? I would really like to find that model for a restoration, I like the Manco

  17. Avataaar/Circle Created with python_avatars shane haws says:

    What I think… your following that acting crap for automotive on TV like trucks and that sort of crap… no more posing for a video clip! Reality not tv….

  18. Avataaar/Circle Created with python_avatars matt shearer says:

    The tank and bars look a little funny in combination with eachother.
    Flat bars maybe?

  19. Avataaar/Circle Created with python_avatars BryDuhBikeGuy says:

    Glad to see you guys are all Ok! Footpegs at the rear axle?Perhaps set the Hand-grip parts of the bars at least 6" forward of the triple tree so you lay forward without twisting your wrists to breaking position.?Your build,so do what pleases you.Have fun guys.

  20. Avataaar/Circle Created with python_avatars shawn mcintyre says:

    That frame won't take the torque you're Fixn' to throw at it !

  21. Avataaar/Circle Created with python_avatars PhatSphinx says:

    Sick lil build I love the repurposing you guys do, big intricate builds are cool but this is something anyone can do with grinder and a 150 quid welder

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